ABD3 MANUAL-360V-50A CD SYSTEM New PDF

Operation manual
Busbar Type Storage Battery Charger

And Discharger
Model
Machine No.
2 49
Contents
I. Specification .............................................................................................................................4
1. FEATURE .......................................................................................................................................4
2. MAIN SPECIFICATION ....................................................................................................................5
II. INSTALLATION ......................................................................................................................8
1. MOVING OF MACHINE ...................................................................................................................8
2. INSTALLATION...............................................................................................................................8
3. LINE CONNECTION ...................................................................................................................... 10
III. Operation manual................................................................................................................12
1. OPERATION ATTENTIONS.............................................................................................................12
2. ALARM ....................................................................................................................................... 12
IV. Maintenance Manual...........................................................................................................15
1. PRODUCT BLOCK DIAGRAM ....................................................................................................... 15
2. INSPECTION BEFORE RUNNING ....................................................................................................15
3. MAINTENANCE AND INSPECTION ................................................................................................ 15
4. CORRECTION .............................................................................................................................. 16
5. MAINTAIN ...................................................................................................................................25
V. Panel controller reference manual...........................................................................................35
1. SUMMARY...................................................................................................................................35
2. FUNCTIONS ................................................................................................................................. 35
3. INTRODUCTION OF PANEL ...........................................................................................................35
4. CONTROL MODE .......................................................................................................................... 41
5. OPERATION PROCESS INTRODUCTION .......................................................................................... 46
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I. Specification
1. Feature
1.1 Application
This machine is suitable for battery charging and discharging and
plate formation.
1.2 Control system
The machine adopts MCU automatic control equipment with a new
generation ARM chip core as its core, which shows Chinese (English)
LCD display interface. It’s shows rich display information (the running
voltage, current, Ah, step time, craft programs, etc.) and alarm
information Over voltage alarm, over-current alarm and low flow alarm,
the output circuit disconnection alarm, busbar voltage alarm, battery
reverse alarm, the initial current abnormal alarm, IGBT drive fault alarm,
parameters read error alarm, program download error alarm, etc
1.3 Function
Working mode of Charge-discharge include constant-current
charging, constant-current voltage limiting charging, constant-voltage
current limiting charging, constant-current discharging, constant-current
constant-pressure discharging, stewing, recycling, time setting, voltage
setting, Ah setting transformation function. Controller has a strong record
function by which you can record running, alarm, operation during its
running as well as real-time clock for analyzing problems of battery
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charging and discharging. Connection to the computer adopts CAN BUS
used in automotive electronic devices used with a high-speed and reliable
transmission.
1.4 Feature
The machine contains programming convenience, high precision,
stable running, safe and reliable features.
2. Main specification
2.1 Specification
Quantity Size Weig
Charge Discharge Output
Model of Length*Width*H ht
Current Current Voltage
Circuits eight mm (Kg)
CDF-360V-C5A -BBU 0~5A None 360V 48 1200*1000*2150 1420
CDF-360V-C10A/D20A-BBU 0~10A 0~20A 360V 24 1200*1000*2150 1200
CDF-360V-C10A/D20A-BBI 30 1200*1000*2150 1360
CDF-360V-30A-BBU 0~30A 0~30A 360V 12 1200*1000*2150 1500
CDF-360V-30A -BBI 9 1100*1000*2150 1400
8 1100*1000*2150 1300
CDF-360V-40A-BBU 0~40A 0~40A 360V 9 1100*1000*2150 1450
CDF-360V-40A-BBI 8 1100*1000*2150 1400
CDF-360V-50A-BBU 0~50A 0~50A 360V 6 1100*1000*2150 1360
CDF-360V-50A-BBI
CDF-360V-C80A/D100A-BBU 0~80A 0~100A 360V 2 1100*1000*2150 1240
CDF-360V- C80A/D100A -BBI 3 1100*1000*2150 1320
CDF-360V-150A-BBU 0~150A 0~150A 360V 2 1100*1000*2150 1160
CDF-360V- 150A -BBI 1220
Remark Different Voltage Current and Circuits can be customized.
2.2 Controlling
Control methods: Digital Tube Display micro-computer controller
automatic controlling.
Process parameter group number: 1groups
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Process parameter step number: 30 steps
Setting method: Control panel keyboard settings or the a
remote settings of computer
Range of parameter setting:
Voltage 0~100%F.S
Current 0~100%F.S
Time 00 :00 ~99 :59
Range of parameter controlling:
Voltage 10% F.S~100% F.S
Current 1% F.S~100% F.S
2.3 Machine Technical Requirements
Power: 3 Phase AC380V (+10%~-5%); frequency is 50HZ±10%
Voltage details should be customized
according to local situation for foreign clients
Full load power consumption: Rated charge current*Rated output
voltage*quantity of circuits*1.1
Sea level: Below 1000m
Humidity: Below 90% nocondensation
Ambient temperature: -5~50
Net voltage fluctuation: Volatility of less than 5%, short-term
fluctuations should not exceed ± 10%
Frequency fluctuations: Below 2%, frequency and network pressure
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changes can not be simultaneously
Installation environment: Without severe vibration and shock, slope
less than 5%, no conductive explosive dust and corrosive
gases or acid gases, operating rooms should be separated
with formation workshops
Date set storage period: 10 years
Attention
Process Setting data
After data input, if the controller is in normal operation
conditions, then the data stored in the controller can maintain for
ten years. The data may be destroyed when there’s malfunction
with controller.
Is strongly recommended that users to the important process
parameters are written down to prevent data loss
2.4 Precision
Current precision ±0.5% F·S F·S=
Voltage precision ±0.5% F·S F·S=
Time precision 24H±15S
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II. INSTALLATION
This machine is fully automatic machine with high demand, which
needs special engineers to install and maintain it. You should read this
specification carefully before operating this machine. After reading,
please will be kept the manual provisions in place;
1. Moving of machine
You should use the forklift truck (whose bearing weight should be
over 2T) to move this machine and pay attention to the center of gravity
position of the machine.
2. Installation
2.1. Be sure to install this machine in suitable place, and ensure the safe
operation and maintenance of this machine.
2.2. Be sure there is enough space around this machine before
installation so that your engineers or technologys can inspect and
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maintain this machine when it is running, also easily for workers’ running
it.
2.3. For charging and discharging machine top mounted a heating
elements, in order to avoid fire accident, it must ensure that charge and
discharge machine top to the top is greater than 1.5 meters workshop
distance, the front and back space is greater than 0.8 meters, and this
distance and workshop in the top no combustible goods.
top of workshop
wall space or other wall space or other
floor
2.4. Keep the installation environment of this machine clean. Don’t
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install this machine in the place where the power supply is not stable or
there is too much sunlight, or this machine can be easily damaged.
2.5. Check the entire accessory after installation and put it in right
place.
2.6. Equipment installation ends and check all accessories, it will be put
away.
3. Line Connection
3.1. Incoming line
Power of the device is three-phase-five-wire three phases inlet
lines connect to three phases circuit breaker Specification for power inlet
line, phase line, null line, ground line should be drawn up according to
full load consumed power. Please refer to the following table.

Full load Specification
Full load
Serial Specification for AC input for phase Null Ground
consumed
Number inlet line breaker line line line line
power(KVA)
current(A) (mm2)
1 50 NM1-250S-125A 75 25 4 10
2 70 NM1-250S-160A 106 35 4 10
3 90 NM1-250S-225A 136 50 4 16
4 110 NM1-250S-250A 167 70 4 16
5 130 NM1-400S-300A 198 95 4 16
3.2. Load output line

5A 10A 20A 30A 40A 50A 80A 110A 160A 200A
1.5mm 2.5mm2
2
4mm2 6mm2 10mm2 16mm2 25mm2 35mm2 50mm 50mm2
2
Specification for load output line should be made according to
charge current. Please check the table above and select. Please see the
marks to figure out the positive & negative poles when wiring.
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Dangerous
Must mounted short-circuit and over-current protection (such as
molded case circuit breaker) in the load line is connected with the
battery, to prevent fire accident caused by the load line due to short
circuit etc!
3.3. Communication wire
If you need to operate the device through pc please connect
communicate line by checking marks, use Cat 5E data cables, please
identify core line according to T568B cross net line.
3.4. Ground connection
Electric control cabinet shell and machine must be in strict
accordance with the national safety standards for electrical grounding.
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III.Operation manual
1. Operation Attentions
1.1 The machine must be operated by qualified operator. The operator
should have professional knowledge and be familiar with safety
precautions.
1.2 If you any abnormalities or alarm is founded during operation, or
alarm information, please immediately stop operation, and inform
professional engineers.
1.3 Equipment in operation process, if the exception are without power
and in restore power equipment to be automatic recovery operation.
1.4 The constant current, constant voltage value should not less than
10% of the rating.
1.5 The location of position should be ventilated, free from rain and
corrosive gas liquid erosion, away from strong magnetic interference.
1.6 Shell of equipment should be well-grounded in order to ensure
personal safety.
2. Alarm
ER00 Panel communication failures
ER01 Parameter set error alarm
ER02 Low current alarm during running
ER03 Over current alarm during running
ER04 Over voltage alarm during running
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ER05 Status abnormal alarm
ER06 Load circuit break alarm
ER07 Read parameter error alarm during running
ER08 Temperature sensor fault alarm
ER09 System clock error alarm
ER10 IGBT drive fault alarm
ER11 High bus voltage alarm
ER12 Low bus voltage alarm
ER13 The initial current exception alarm
ER14 Battery reverse connect alarm
ER15 Data memory read fault alarm during running
ER16 Correction parameter wrong alarm during running
ER17 Current AD sampling out of limit alarm
ER18 High discharge twinkling bus voltage alarm
ER19 Temperature sensor fault alarm
ER20 Excess temperature alarm
ER21 Communication disconnection alarm during

temperature control charging
ER22 GENSET parameter error alarm
ER23 Power grid status data invalid alarm
ER26 GENSET step parameter out of limit alarm
ER64 Correction parameter error alarm
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ER65 Read correction parameter error alarm
ER66 Read system parameter error alarm
ER67 Read system parameter error forbid running alarm
ER68 Stop storage read error alarm
ER80 Technology download mode alarm
ER81 Technology download control voltage alarm
ER82 Technology download current alarm
ER83 Technology download time alarm
ER84 Technology download record time alarm
ER85 Technology download Ah alarm
ER86 Technology download temperature alarm
ER87 Technology download enabled alarm
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IV. Maintenance Manual
1. Product Block Diagram

power input
Three phase transformer&Three

Phase Bridge
Voltage current Charging and discharging

IGBT Driving circuit
sampling circuit IGBT
Isolation
contactor Contactor run/Stop signals
storage Drive pulse

battery
Voltage current signal

A/D converter I/O circuit
Power circuit CPU
Serial communication line
Data
memorizer LED, keyboard
Microcomputer controller
2. Inspection before running
Items Requirements
Cooling fan SCR cooling fan operation normal, SCR can
be reliable cooling
Dc power buffer Power is connected, buffer contactor (KM1,

contactor KM2) time delay and absorption.
3. Maintenance and inspection
For the safe use of the controller, please carry on the following
maintenance tasks according to the regulated run-time intervals
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Interval
Items Requirements Each Each Each Each
Seldom
day week month Year
Parameter Preset technology
setting parameter, confirm
the right storage of
parameter
System System parameter
parameter is consistent with
machine model
Current Current accuracy
Measurement within allowed
error range
Voltage Voltage accuracy
Measurement within allowed
error range
Input and No loose joints
output signal
lines connect
Input and No visible damage,
output signal no broken
line
appearance
Ground wire No loose joints
connection
Ground Line No visible damage,
Appearance no broken
The main No loose joints
circuit wiring,
copper bars to
connect
Main circuit No visible damage,
wiring, copper no broken
appearance
Fan for In normal
cooling operation, no noise
The control Board keep clean
circuit board
to appearance
Inner machine Clean dust, keep
control cleaning
cabinet
4. Correction
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Description
4.1 Setting System Parameters
Standby
Rated voltage setting
Voltage decimal point setting
Rated current setting
Current point setting
Current point setting
Software version number
Restore the factory default

password input (if the
calibration parameter deviation
is too large, try to restore the
factory settings) Numerical input key
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Enter password
Setting/Check
Restore Factory Successful setup
Any key Setting/Check
Return password Input
Restore Factory Setup failed
Any key
Return password Input
4.2 System Parameter Calibration
4.2.1 Calibration tool
The 3 and a half multimeters that have passed the test (the DC voltage
file with DC millivolts and the rated voltage value of the equipment),
the shunt (accuracy of 0.5 or above, the range is the rated value of the
equipment).
4.2.2 Analog Zero (Offset) Correction
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Standby
Correct battery voltage zero
Set/view
Battery voltage zero data flashes,

waiting for confirmation
Set/view
Battery voltage zero

correction completed
Calibrate the bus

voltage zero
Set/view
Bus voltage zero data flashes,

Set/view
Bus voltage zero correction

completed
Correct current zero
Set/view
Correct current zero data flashes,

Set/view
Current zero correction

completed
If the zero value deviation is too large,

the system will not allow calibration
and prompt ER16 alarm. This may be
caused by a motherboard hardware
circuit failure.
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4.2.3 Current 10% Full (Gain) Correction
Note: The charging and discharging currents need to be corrected
separately.
Set the charging or discharging

process: voltage 0, current 10%
rating, time 10 minutes and
running
Current full bit wait for

correction
and adjust the actual current (the

multimeter detects the shunt mV value)
to match the 10% rated current. Set/view
Corrected
Run/pause
Return to the running interface
If the calibration parameters exceed

the normal range, the system will
not allow calibration and prompt
the ER16 alarm! Any key
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4.2.4 Current 100% Full (Gain) Correction
Note: The charging and discharging currents need to be corrected
separately.
Set the charging or discharging

process: voltage 0, current 100%
rating, time 10 minutes, and run
view
Current full bit wait for

correction
actual current, and adjust the actual

current to match the 100% rated
current (the multimeter's detection
Set/view
shunt mV value).
Corrected
Set/view

the normal range, the system will not
allow calibration and prompt the
ER16 alarm!
Any key
Return to the running

interface
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4.2.5 Bus Voltage Full Level (Gain) Correction
Standby mode
Bus voltage full bit wait for

correction
Numerical input Cancel

correction
Enter the actual value of run/pause
the bus voltage
Set/view
Flashing, waiting for

confirmation
Set/view
Bus voltage correction

completed
If the calibration parameters

exceed the normal range, the
system will not allow calibration
and prompt the ER16 alarm!
Any key
Return to standby interface
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4.2.6 Battery voltage full (gain) correction
Set the rest process for 10

minutes, connect the rated
number of batteries, and run
Current full correction
Battery voltage full bit waiting

for correction
Numerical input Cancel

correction
Enter the actual run/pause
battery voltage value
Set/view
Flashing, waiting for

confirmation
Set/view
Confirm that the battery

voltage is corrected

the normal range, the system will
not allow calibration and prompt the
ER16 alarm!
Any key
Return to standby interface
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4.2.6 Recover default parameters operations
When the controller parameters were disordered, if it cannot recover by
normal operation, operator can recover default parameters;
Note: after recover default parameters, controller preset 6 steps
calibration technology. All parameters need to be recalibrated.
Standby mode
tage & Settings / View
Rated voltage setting
tage
Restore factory setting
Numerical input
Enter password
Settings / View

succeed Settings / View
Stop

fail
Any key
Return enter password
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5. Maintain
Before perform of maintenance, you must thoroughly read and
understand the Micro-computer controller reference manual”.
5.1 Notes on maintenance
Danger:
5.1.1 Before work, be sure to disconnect the power supply, for
equipment big DC bus capacity capacitance, after 10 minutes (DC1000V)
check with the voltmeter remaining voltage to verify equipment DC bus
voltage drop to a safe range.
5.1.2 Although still has power, but due to the light bulb has burnt out,
the indicator may not bright. When using the indicator check whether
there is electricity, need to verify the indicator light of electrify main
source is normal.
5.1.3 If the power is connected in, need maintenance work, don't touch
the following parts and cable, because there is a high voltage,
maintenance engineers must work on the plate on the insulation and bring
insulation glove. Contact the following components may lead to serious
accidents because of electric shock, and even death.
----Control of the power supply fuse.
----Main control circuit board (Main control circuit board is
CDF-BB-CD PCB) of switch power supply.
----The main control circuit board JK3, JK4 terminals.
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----AC220V coil voltage of the relay, contactor.
5.1.4 In any case for maintenance work, be sure to disconnect the load
connection, otherwise in touch control circuit board and is the main loop
electric shock risk.
5.1.5 If during maintenance to put your hands in frame, be sure to wear
insulating gloves. Can't use naked hand maintenance work, or you will
hurt, such as hand in parts corner scratch.
5.1.6 In the light of bad ban maintenance work working in the dark
light will lead to wrong under or contact with dangerous part, cause
serious danger or even death.
5.1.7 Unable to change any part of the circuit board and, when
necessary, change the whole piece of circuit board
5.1.8 For DC bus parallel air switch, please respect strictly the
following instructions to avoid the machine damage and operator security.
5.1.8.1 The procedure of switch on:
----Switch on the AC power (QF1);
----Make sure that DC bus bar parallel air switch (QF2) bottom DC
voltage is normal (>machine DC Voltage);
----Check the DC bus bar parallel air switch(QF2) upper DC voltage,
if the voltage difference with bottom DC voltage <100V, Please
switch on the DC bus bar parallel air switch;
----If the DC bus bar parallel air switch(QF2) upper DC voltage= 0 V,
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make sure that all chargers DC bus parallel air switch are in OFF
position, then switch on the DC bus parallel air switch;
5.1.8.2 Maintenance: To ensure operator safety during maintenance,
machine power (QF1) and DC bus parallel air switch (QF2) must be in
OFF position. The machine has a large capacity storage, when the power
is off, be sure to check the DC bus voltage is less than the safe voltage
DC36V, then you would start the maintenance work.
5.2 Trouble Shooting
5.2.1 Failure Failed to be detected

1 Display panel not bright
Symptoms Reasons Solution
Main control board Change control board
power is unusual, board
When the power PWR LEDs not bright
supply, display panel Display panel and Change the connection line
not bright control board
connections to the fault
Display panel failure Change display panel
2 Microcomputer controller keyboard failure

Symptoms Reasons Solution
The key on the The keyboard connection Replace the keyboard
keyboard no reaction row line fault or buttons
failure
Display panel failure Change display panel
5.2.2 Alarm instructions and corrective measures

Alarm name Panel communication failures
Alarm information ER00
Detection method After display panel get on power, exchange
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communication testing information with control board,
detection abnormal alarm.
a. Communication connection line breakdown
line
b. Connector poor contact Clean up the connector,
Reason/Solution
ensure reliable contact
c. Main control board failure
d. Display panel fault
Alarm name Operation of owe flow
Controller start after the operation, 3 seconds to
current value not set value, or to set data after testing
Detection method
and current value is less than the set value, a controller
"operation of owe flow" alarm
a. DC power fuse
b. Contactor for load output poorly connected
Reason/Solution
Alarm name Operation of over flow
Controller start after the operation, detection current

Detection method value greater than the set value, controller send out "
operation of over flow" alarm.
a.
restart to correct the current
b. No battery voltage showing, Warning for overflow
Reason/Solution
loading wire, checking the wire line.

Alarm name Operation of over-voltage
Detection method Constant pressure the current limit way of working
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controller start after the operation, testing voltage
value greater than the set value, a controller "operation
of over voltage" alarm.
a. The setting controlling voltage cannot match the

Reason/Solution voltage value of battery e value
b. Main control board failure
Alarm name Status abnormity alarm

Alarm ER05
After controller startup, charger running status not
Detection method
accord with actual technology.
Reason/Solution Main control board failure e the board.
Alarm name Load circuit disconnect during running

Alarm ER06
After controller startup, if current can’t reach set
value in 3 seconds, or reaching the set value, the
Detection method testing current <set value, and the battery
voltage >machine rated voltage, controller will alarm
for “load circuit disconnect during running”
a. The load circuit breaker disconnects
switch on.
b. Switch on the load breaker to run the machine and
then the load breaker trip immediately
Reason/Solution
the board.
c. Battery wire was disconnected or battery short
circuit testing battery wire and replace the
battery with new one.
Alarm name Read error parameters alarm
Controller start after the operation, reading the stage
set technology program, detection set values is not
Detection method
within the scope of a controller "parameters read error"
alarm.
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a. Process parameters set wrong Reset process
parameters.
Reason/Solution
b. Main control board memory chip fault
control board.
Alarm name IGBT drive fault alarm
Controller start after the operation, warning start after
Detection method
checking out the failure signal of IGBT drive.
a. IGBT driving wire connecting wrong Check the
wiring, eliminate the connection problems.
Reason/Solution
b. IGBT is damaged
Alarm name High bus voltage alarm
After discharging, detection a higher than upper limit
Detection method
value of busbar voltage alarm.
a. DC power circuit breaker was disconnected or the
fuse fusing Switch on the breaker or replace
Reason/Solution fuse.
b. Discharge control board failure
discharge control board.
Alarm name Low bus voltage alarm
After Charging, detection of busbar voltage less than
Detection method
machine rated value alarm.
a. DC power circuit breaker was disconnected or the
fuse fusing Switch on the breaker or replace
fuse.
Reason/Solution b. Network voltage is too low mains
supply.
c. Discharge control board failure Replace
Alarm name Current AD zero abnormal alarm
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After the charge and discharge program run, detection
Detection method
current AD zero higher than normal alarm.
a. Current AD zero variation in Standby mode
Reason/Solution recalibration of current AD zero.
b. Main board failure Replace Main board.
Alarm name Battery reverse connect alarm
After the charge and discharge program run, detection
Detection method
to battery reverse connect alarm (voltage<-1.0V).
a. Battery reverse connect Replace the battery
connection.
Reason/Solution
b. Discharge control board failure Replace
Alarm name Data memory fault
Alarm information ER15 ER68
Inability to read and write normal storage, controller
Detection method
will alarm
Reason/Solution Memory chips failure Replace the memory chip.
During running the correction parameter wrong
Alarm name
alarm
During controller running, if controller correction
Detection method
parameter (current, voltage, etc.) is abnormal, alarm.
a. Main board voltage, current correction range is too
Reason/Solution big recalibration of current Sand voltage.
b. Main board failure Replace Main board.
Alarm name Current sampling out of limit alarm
Controller start after the operation, current AD
Detection method
sampling value out of limit;
c. Main control board program mismatching Reset
main board factory setting.
Reason/Solution
d. Main control board failure
main control board.
Alarm name Instant Bus Voltage Overtop
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After controller startup, detected busbar voltage
Detection method
exceed busbar voltage upper limit.
a. DC power circuit breaker was bad connect
check the breaker or replace fuse.
Reason/Solution
b. Discharging main
Replace the board.
Alarm name Temperature sensor failure warning
Operation temperature control charge mode,

Detection method
corresponding loop temperature -327.68
a. The corresponding temperature sensor of loop

disconnected examine sensor connect line.
Reason/Solution
b. Temperature sensor was damaged Replace
temperature sensor.
Alarm name Excess temperature alarm
Alarm message ER20
Operation temperature control charge mode, the
Detection method detected temperature excess ceiling temperature 5
minutes alarm.
a. Temperature arrived upper limit, according to the
setting technology parameter run, the temperature
can’t fall below the upper limit in a limited time
Reason/Solution b. Temperature sensor fault change temperature
sensor.
c. Temperature Replace the
board.
During temperature control charging,
Alarm name
communication break off alarm
Alarm message ER21
Operation temperature control charge mode, loop
Detection method communication break off (can’t get temperature data
by communication mode).
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a. Communication connect line fault change
connect line.
b. Temperature Replace the
Reason/Solution
board.
c. Meso-position c Replace
the board.
Alarm name GENSET parameter error alarm
Alarm message ER22
Operation GENSET charge mode, GENSET enable
Detection method
parameter abnormal alarm
GENSET charge technology parameter error
Reason/Solution
examine technology and download again.
Alarm name Power grid status data invalid alarm
Alarm message ER23
When the loop electrify, can’t receive valid power
Detection method
grid status in 50 seconds.
The loop not received valid signal of power grid
Reason/Solution examine power grid status input signal at
meso-position.
Alarm name GENSET step parameter over limit alarm
Alarm message ER26
Operation GENSET charge mode, GENSET step
Detection method
parameter abnormal alarm
GENSET charge technology parameter error
Reason/Solution
examine technology and download again.
Alarm name Correction parameter wrong alarm
During the current correction, checks out that setting
value is not the 10% or 100% of rating value, the
Detection method
correction parameter testing more than the normal
range alarm.
a. Wrong current setting value
the current controlling value.
Reason/Solution
b. Inputting parameter of voltage correction exceed
the normal range Restart and input the voltage
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correction parameter.
Alarm name Read the correction parameter wrong alarm
Testing to Main control board voltage, current has not
Testing been carried out correction or calibration parameter in
abnormal alarm.
a. Main control board voltage, current has not been
carried out correction Correction voltage,
Reason/Solution electric current.
b. Main control board failure main control
board.
Alarm name Read the system parameter wrong alarm
Alarm information ER66, ER67
Test to the system parameters not set or abnormal
Testing
alarm system parameters.
a. Not the setting system parameters Sets the
system parameters
Reason/Solution
b. Discharge control board failure
Alarm name Parameters download alarm
Mode download wrong ER80
Voltage download wrong ER81
Current download wrong ER82
Download time error ER83
Alarm message Record the time download mistakes ER84
Ah download wrong ER85
Temperature download wrong ER86
Enable download wrong ER87
When the FPMS download a program to controller,
checking process parameters of download is exceed
Detection method
the machine rating value, controller will send out the
corresponding "parameters" alarm.
Reason/Solution Check on the technology process rewritten.
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V. Panel controller reference manual
1. Summary
Controller using advanced 32 bit of single chip microcomputer, and
monitoring of the computer connected by using high-speed reliable CAN
BUS. And charge and discharge into supporting the use of the machine,
and can be widely used in battery, the battery into the plate into.
2. Functions
2.1 Through the controller realize stalling, constant current charging,
constant pressure charged, and constant exile into electricity, etc) control
mode, set voltage, current and voltage, the time, the parameters of the
current transition conditions, to achieve production charge and discharge
process of automatic execution.
2.2 Through the controller of process, can prepare 30 different stages.
2.3 With pressure, flow, owe flow, set data error, read the process
parameters, the download data errors and mistakes of busbar voltage
over/under voltage, battery reverse connect and alarm function.
2.4 Records to 100 group operation, operation or alarm data, and record
the record of the clock produced, all of the equipment operation can be
inquires state.
3. Introduction of panel
3.1. key panel layout see the map
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Figure 1 controller panel
3.2. Introduction of keyboard
This panel of seven key to operation, the key function definition in
table 1
Name Function
a. Controller in standby mode, press the button to enter operation,
start option in the screen, then press the key system is from choice
began to run.
b. The controller is running, press the button to enter suspended
state.
c. A controller is in a suspended state, press the key to enter running
state.
a. Controller in standby mode, press the button is invalid.
b. The controller is in operation or suspended state, press the button
end run, back to standby mode.
c. A controller is in a process set son set parameters state, press the
button return to choose process work way set state, then, press the
button saves the current parameters, back to standby mode.
36 49
d. A controller is in a process system parameters set (or zero
correction, with a correction) state, press the button immediately
exit the current operation, back to standby mode.
a. Controller in standby mode, press the button to enter process set
state.
b. In the process program under the picture, according to the button
to enter the current stage of the son set parameters, then press the
switch to the next set parameters, is as follows: voltage, current,
time, the current work in different ways, the number of
parameters can be set son different, be over after, then press the
button to enter the next phase of the process parameters set.
c. The controller is running, press the button to enter in the operation
of the check process picture.
d. The controller is in operation process to view images, according
to the key returning operation picture.
a. In operating or standby mode, press this button and
button together;
b. A controller is in a process set the state picture, according to the
key set way, continuous according to the key can in various ways
of working either .
c. A controller is in a process set (or system set parameters, zero
correction, with a correction) state quick snip of the shear
parameters set frame, according to the key can modify the current
flashing a numerical, can a single button can also be continuous
buttons, increase the current value.
button together;
b. The controller is running, press the button to show the real-time
alternately working parameters of (voltage, current, time,
capacity).
c. The controller is in operation process view picture, according to
the key can alternate shows corresponding technology parameters
of the stages.
d. A controller is in a process set (or system set parameters, zero
correction, with a correction)
37 49
e. State quick snip of the shear parameters set frame, according to
the key can modify the current flashing a numerical, can a single
button can also be continuous buttons, reduce the current value
button together; you would then set the system
parameters;
b. A controller is in system parameters (or zero correction, with a
correction) set selection screen, press the button to switch to a son
of the parameters can be set status screen.
c. A controller is in a process work under way when set state, press
the button to switch to a stage of the process set.
d. A controller is in a process set (or system set parameters, zero
parameters set picture, this key used to move to the left of that can
be modified flashing digital.
e. A controller is in a process view state, press the button to switch
to a stage of the process inspection.
a. A controller is in system parameters (or zero correction, with a
correction) set selection screen, press the button to switch to a son
of the parameters can be set status screen.
b. A controller is in a process work under way when set state, press
the button to switch to the next phase of the process set .
c. A controller is in a process set (or system set parameters, zero
parameters set picture, this key used to move right can be
modified flashing of digital display.
d. A controller is in a process view state, press the button to switch
to the next phase of the process inspection.
3.3. Controller indicator introduction
3.3.1. The controller is running, manual switching display the current
working parameters or check already set parameters (voltage, current,
time), voltage, current, time indicator and display content corresponds.
38 49
3.3.2. When the controller is running or set of process parameters,
charging and discharging, quiet place indicator and the mode
corresponding instructions.
3.3.3. The controller is running, running lights lighting; Alarm when the
alarm indicator lights lighting, running lights flashing.
3.3.4. Controller parameters set indicator lighting; In the operation of
the check has set parameters, set indicator lights flashing.
3.3.5. Controller standby, if not connect battery, then all indicator light
are off, or voltage indicator on, says the battery voltage.
3.3.6. Controller and the upper machine online communication,
communication indicator lighting.
3.4. Controller digital display description
Introduction
1 -- The first time when power on the controller,

-- ----
---- digital display flash shows "-", about 5 ~ 6 seconds.
Standby that interface, if meet has a battery, the
2 --
-- "stop" in the position of the display the current
stop
battery voltage.
From standby mode, when activated, showed
3 01
that the interface, 01 flashing, said can choose to
=run
start stage number.
4 01 Work mode set display screen, says 01 stage for
Cyc.S circulation beginning mode
5 01 01 stage for circulation said end mode, its
Cyc.E subparameters can be set cycle times.
6 01 01 stage for constant current said charging mode, its

subparameters can be set convert voltage, charging
CH-A current, stage time.
39 49
01 stage for constant pressure said charging
7 01 mode, its subparameters can be set to control the
CH-U voltage, charging electric current, stage time and
convert current.
01 stage for constant current discharging model,
8 01
its subparameters can be set discharge termination
dH-A
voltage, discharge current and stage time.
9 01 01 stage for stalling said mode, its
IDLE subparameters only stage time.
10 01
01 stage for end mode.
=End
11 02
02 stage for technology end mode.
E-ST
12 01 If in the operation press "start /pause", the
PAUS current work suspended, display the picture.
Said work report to the police, call the police
13 01
code for 06, which in the picture "Er06" twinkle
Er06
display.
14 FU System parameters set son picture, indicates
400.0 that the battery voltage range of 400.0.
15 PU System parameter, the decimal digits show
0001 voltage display for one.
16 FC The system parameters, said current full range
9.999 of 9.999 A namely 10 A.
17 PC The system parameters, said the current show
0003 the decimal point digits for three.
The system parameters, said the current in the
18 Ad
circuit CAN network ID for NO.128, the ID in the
0128
same network must ensure that its uniqueness.
19 u0 Zero adjustment screen, indicates that the
000.0 battery voltage zero adjustment.
20 b0 Zero adjustment screen, said bus voltage zero
000.0 adjustment.
21 c0 Zero adjustment screen, said current zero
0.000 adjustment.
40 49
22 UF A full picture correction, indicates that the
206.0 battery voltage full a correction.
23 bF A full picture correction, said a full bus voltage
000.0 calibration.
24 CF A full picture correction, said the current work
0.000 with a correction, running state can be used.
4. Control mode
Microcomputer controller has quiet place, constant current charging,
constant pressure the current limit charged, and constant electric and so
on many kinds of control ways exile.
4.1 Process key parameters introduction
A. Stage
This option is used for select a set of process parameter of stage
which is needful.
B. Mode of operation
This option is used for select this stage in what way to control
operation. The control mode: stalling IDLE, constant current charging
CH-A, constant pressure the current limit charging CH-U, constant exile
electricity dH-A, circulation began to Cy-S, circulation Cy-E, and END
over END, etc.
C. Current
The charger, discharge work under way must be set, as a storage
battery charging and discharging current control values.
D. Voltage
41 49
The constant current charging, constant exile-electricity as a
working way conversion condition. In the constant pressure charging
work must be set in the way, as a storage battery charging of constant
pressure control voltage.
E. Transition conditions
The transformation of the controller condition is running time,
testing phase voltage and charge current (only in constant pressure charge
useful).
Attention
If setting two or more conditions, as long as there is a transition
conditions meet start up the conversion.
In the set convert conditions, other invalid conditions must be set to zero.
Timing conversion: when set stage running time transition conditions,
other transition conditions are the zero, according to the process of the
controller set control mode launch at the time, until the time to set a time, this
period end.
Voltage conversion: when set the constant pressure transition conditions
(only in constant current charging, constant exile under way can be set to
electricity), and the other transition conditions are the zero hour, according to
the process of the controller set control mode run, in charge when the battery
voltage is greater than the control group voltage value, this period end; When
the battery pack in discharge when voltage less than control voltage value, this
period end.
Charging current transition: charging current transition in constant
pressure the current limit only charge method can be set down, when set charge
current transition conditions, other transition conditions are the zero hour,
according to the process of the controller set constant pressure the current limit
control mode operation, when the battery voltage to the group to control the
voltage, when charging current small and set the charge current transition
42 49
conditions, this period end.
F. Circulation body
Controller cycle body have cycle starting point Cy-S, circulation end
Cy-E, recycle number three Settings.
Attention
Controller for single circular body, can't use nested
G. Record time
If the record set time (only in PC set), in the operation process, the
controller will be in accordance with the setup time record real-time data
Attention
Most controller can be a record 100 sets of data, if the record number
more than 100 groups, the back of the records to be automatic covering the first
record
Every time after the launch will cover the last start running record data.
When the record time for the zero , records the time for default controller
for 10 minutes.
4.2 Control mode introduction
A. IDLE stalling
According to the set time, storage battery charging and discharging
stop.
B. Constant current charging CH-A
Controller with constant current charge to load. Transition
conditions have stage time, voltage, Ah.
43 49
C. Constant pressure and limit current charging CH-U
Controller first at constant current charging for storage battery group,
when the battery voltage arrived the set value, reduce gradually charging
electric current, while maintaining constant voltage battery pack, form
Juan flow charge. Transition conditions include time, charging electric
current, stage Ah.
Attention
Set the control current value to select the right value, when the current value too
big when, easy to cause the control voltage overshoot. When the current value
an hour, the control voltage is hard to reach a set voltage.
D. Constant electric charge or the exile dH-A
Controller of constant current battery pack for electric discharge.
Transition conditions include time, voltage, Ah, etc.
Attention
When charging and discharging machine for plate into, set to work is to give
way to discharge the plate charging.
E. Set cycle began to CY-S
Set cycle to begin is set up and the loop ends supporting the use, it is
a single body, can't use nested
Attention
Process can't from the stage start operation cycle body, or program will not
normal operation.
F. Set the loop ends CY-E
When a process program cycle body set, after the completion of the
44 49
program must be the end of the last step set cycle the end point. In the
loop ends mode can be set to recycle number, the biggest 9999.
G. END
The end of a process instructions. Each a complete process must
have end instruction or technology end instruction, to guarantee the
proper operation of the program.
H. Technology end E-ST (it can’t be set, only for check)
The end of a process instructions. Each a complete process must
have end instruction or technology end instruction, to guarantee the
proper operation of the program. When the machine running to this mode,
controller at technology run end status, panel change to shows E-ST and
voltage. After stop operation, the controller will return standby status.
45 49
5. Operation process introduction
5.1 Parameters input process
46 49
5.2 Start running process
47 49
5.3 Check it in operation process
5.4 Numerical input
Through the " / stage /stage" key choose to change a numerical,
value.
48 49
49 49
PATH : I:\NEW ROLE\01.IGBT BASED CD CHARGERs\1.JOBS 2020-21\5200002811\PRD DOC\
ITEM CODE:
JOB NO :
230VAC,1PH
CUSTOMER SCOPE
/ACI.B2 R-PH
/IC1.E3
/IC1.F3
H71
R-PH R-PH
/ACI.E2
-FA1
H4
-FA2
-FA3
/CTRL.E2
H20 H4
X1
X2
/CTRL.E2
H6
H21
1 NC
/IC2.D6
H111
H213 /IC2.D6
H113
H215 /IC2.D6
H115
ITEM CODE:
JOB NO :
H271
H171
6 5 4
6 5
4
3 2 1
3 2
1
H251
CT
CT
CT CT
1DC+
+
+
+
+
1DC-
/IC1.E7
/IC2.E6
1DC- - +
1DC+
1DC+
-R1
1DC-
ITEM CODE:
JOB NO :
H12
-FAN1* -QF11
H10 H10
-TM1:Z1
/ACI.E6
-QF17
a121 2 1 H11 H11
/ACI.E6
-TM1:Z2
N L
-FAN2*
H12
N L
230VAC,1PH
H12
H12
N L
-QF10:1
N L 1 NC
H25 H25
H31 /CTRL.E4
-NT2:1
H27 H27
/ACI.F6
H33
/IC2.D3
-CN29:2
10 Way 10 Way
ITEM CODE:
JOB NO :
H12
A1
A2 -QF10:1 H25
/CTRL.E4
1 NC -NT2:1 H27
/ACI.F6
106
10 Way 10 Way
ITEM CODE:
VARIANT :
SPECIAL NOTE:COMMUNICATION
CABLE 4CORE NEED TO BE
TWISTED
-1QF2
1J3 2 1
-1QF3
2 1 4 3
1J11 1J9 1J7
1J13 -1QF1
-1FU -1R2 1
1J5 1J3 1J1 2 1DC+
4 3
1J15 1J4
+
-1R3 3
1J4 1J2 4 1DC-
JK4
BT+ 1
JK3
BT- 2
YELLOW
1 FL+ H41
BLUE DC-DC BD IGBT KA_2 3
2
FL- H22
N 4
6 5
5
1K1 H23
L
6 -1QF1
KA_1 1K2 H12 H12
JK5 /IC1.E1
1
/DCDC-1.D2
1J5 1 C1 JK2
1J5
GRY
1K4 G1 1
2
R 2 1
1K5 2 -1RC. -1RC
3 E1
1K6 Y 4 3
G2
BL
1K7 5 4
BK E2
V G H L
JK1
1
2
3
4
TO CKT-2(PC10-JK1)
-2QF2
2J3 2 1
-2QF3
2 1
2J11
2J9 2J7 4 3
2J13 -2QF1
-2FU -2R2 1
2J5 2J3 2J1 2 1DC+
4 3
2J15 2J4
+
-2R3 3
2J4 2J2 4 1DC-
JK4
BT+ 1
JK3
BT- 2
YELLOW
1 FL+ H41
2
FL- H22
N 4
6 5 H23
5
2K1
L
6 -2QF1
KA_1 2K2 H12 H12
JK5 /IC1.E1
1
/DCDC-1.E7
2J5 1 C1 JK2
2J5
GRY
2K4 G1 1
2
R 2 1
2K5 2 -2RC. -2RC
3 E1
2K6 Y 4 3
G2
BL
2K7 5 4
BK E2
V G H L
JK1
1
2
3
4
FROM CKT-1(PC9-JK1) &TO
CKT-3(PC11-JK1)
ITEM CODE:
VARIANT :
TWISTED
-3QF2
3J3 2 1
-3QF3
2 1 4 3
3J11 3J9 3J7
3J13 50LET -3QF1
-3FU -3R2 1
3J5 3J3 3J1 2 1DC+
4 3
3J15 3J4
+
-3R3 3
3J4 3J2 4 1DC-
JK4
BT+ 1
JK3
BT- 2
YELLOW
1 FL+ H41
2
FL- H22
N 4
6 5
5
3K1 H23
L
6 -3QF1
KA_1 3K2 H12 H12
JK5 /IC1.E1
1
/DCDC-2.D2
3J5 1 C1 JK2
3J5
GRY
3K4 G1 1
2
R 2 1
3K5 2 -3RC. -3RC
3 E1
3K6 Y 4 3
G2
BL
3K7 5 4
BK E2
V G H L
JK1
1
2
3
4
FROM CKT-2(PC10-JK1)
&TO CKT-4(PC12-JK1) -4QF2
4J3 2 1
-4QF3
2 1
4J9 4J7 4 3
4J11
4J13 -4QF1
-4FU -4R2 1
4J5 4J3 4J1 2 1DC+
4J15 4J4
3
+
-4R3 3
4J4 4J2 4 1DC-
JK4
BT+ 1
JK3
BT- 2
YELLOW
1 FL+ H42
2
FL- H22
N 4
6 5 H23
5
4K1
L
6 -4QF1
KA_1 4K2 H12 H12
JK5 /IC1.E1
1
/DCDC-2.E7
4J5 1 C1 JK2
4J5
GRY
4K4 G1 1
2
R 2 1
4K5 2 -4RC. -4RC
3 E1
4K6 Y 4 3
G2
BL
4K7 5 4
BK E2
V G H L
JK1
1
2
3
4
&TO CKT-5(PC13-JK1)
ITEM CODE:
VARIANT :
TWISTED
-5QF2
5J3 2 1
-5QF3
4 3
5J11 5J9 5J7
5J13 -5QF1
-5FU -5R2 1
5J5 5J3 5J1 2 1DC+
5J15 5J4
+
-5R3 3
5J4 5J2 4 1DC-
JK4
BT+ 1
JK3
BT- 2
YELLOW
1 FL+ H42
2
FL- H22
N 4
6 5
5
5K1 H23
L
6 -5QF1
KA_1 5K2 H12 H12
JK5 /IC1.E1
1
/DCDC-3.D2
5J5 1 C1 JK2
5J5
GRY
5K4 G1 1
2
R 2 1
5K5 2 -5RC. -5RC
3 E1
5K6 Y 4 3
G2
BL
5K7 5 4
BK E2
V G H L
JK1
1
2
3
4
&TO CKT-6(PC14-JK1) -6DF2
6J3 2 1
-6QF3
2 1
6J11 6J9 6J7 4 3
6J13 -6QF1
-6FU -6R2 1
6J5 6J3 6J1 2 1DC+
4 6J15
6J4
3
+
-6R3 3
6J4 6J2 4 1DC-
JK4
BT+ 1
JK3
BT- 2
YELLOW
1 FL+ H43
2
FL- H22
N 4
6 5 H23
5
6K1
L
-6QF1
6 H12 H12
KA_1 6K2 /IC1.E1
JK5
1
/DCDC-3.E7
6J5 1 C1 JK2
6J5
GRY
6K4 G1 1
2
R 2 1
6K5 2 -6RC. -6RC
3 E1
6K6 Y
4 3
G2
BL
6K7 5 4
BK E2
V G H L
JK1
1
2
3
4
&TO CKT-7(PC15-JK1)
ITEM CODE:
VARIANT :
TWISTED
-7QF2
7J3 2 1
-7QF3
2 1 4 3
7J11 7J9 7J7
7J13 50LET -7QF1
-7FU -7R2 1
7J5 7J3 7J1 2 1DC+
4 3
7J15 7J4
+
-7R3 3
7J4 7J2 4 1DC-
7J9
JK4
BT+ 1
JK3
BT- 2
YELLOW
1 FL+ H43
2
FL- H22
N 4
6 5
5
7K1 H23
L
6 -7QF1
KA_1 7K2 H12 H12
JK5 /IC1.E1
1
/DCDC-4.D2
7J5 1 C1 JK2
7J5
GRY
7K4 G1 1
2
R 2 1
7K5 2 -7RC. -7RC
3 E1
7K6 Y
4 3
G2
BL
7K7 5 4
BK E2
V G H L
JK1
1
2
3
4
&TO CKT-8(PC16-JK1) -8QF2
8J3 2 1
-8QF3
2 1
8J11 8J9 8J7 4 3
8J13 -8QF1
-8FU -8R2 1
8J5 8J3 8J1 2 1DC+
4 3
8J15 8J4
+
-8R3 3
8J4 8J2 4 1DC-
8J9
JK4
BT+ 1
JK3
BT- 2
YELLOW
1 FL+ H43
2
FL- H22
N 4
6 5 H23
5
8K1
L
6 -8QF1 H12 H12
KA_1 8K2 /IC1.E1
JK5
1
/DCDC-4.E7
8J5 1 C1 JK2
8J5
GRY
8K4 G1 1
2
R 2 1
8K5 2 -8RC. -8RC
3 E1
8K6 Y
4 3
G2
BL
8K7 5 4
BK E2
V G H L
JK1
1
2
3
4
&TO PC23(JK3)
ITEM CODE:
JOB NO :
INV CTRL SUPPLY
180V AC
H13
/DCDC-3.D9 H43 /DCDC-2.D9 H42 /DCDC-1.D4 H41
/DCDC-4.D4 /DCDC-1.D9
/DCDC-3.D4
/DCDC-4.D9 /DCDC-2.D4
H41
H43 H43 H42
H23
H22
H12 H12
ITEM CODE:
JOB NO :
H22
H23
TO NEXT SYSTEM
JK2 JK1
+5VC H L FC N L
GND CAN
-PC23.JK1
TH CAN POWER SUPPLY BD
TL -PC23.JK3
U21 CAN
/Com2.E4 U21 +5V G H L
GRID U22 JK3
/Com2.E4 U22
/Com2.E4
U23
U23
GENST U24
/Com2.E4 U24
h
l
ON CD SYSTEM-1
-HBL1
1 1A 2 1L
CBT-1_GP1
2L
ON CD SYSTEM-2
-HBL2
1 1A 2 1L
CBT-2_GP1
2L LINE
NEU
ON CD SYSTEM-3
-HBL3
1 1A 2 1L
CBT-3_GP1
2L
ON CD SYSTEM-4
-HBL4
1 1A 2 1L
CBT-4_GP1
2L
ON CD SYSTEM-5
-HBL5
1 1A 2 1L
CBT-5_GP1
2L
ON CD SYSTEM-6
-HBL6
1 1A 2 1L
CBT-6_GP1
2L
ITEM CODE:
JOB NO :
220VAC
POWER SUPPLY
L
N
/Com1.D3
U21 GR1_1
GRID 24+
U5
/Com1.D3
U22 GR1_2
U23 5V1
/Com1.D3 GS1_1
GENST U24 5V2
/Com1.D3 GS1_2
GRID PP
U25 GENSET PP
GR2_1 U6
U26 101
GR2_2 U7
U27 201
GS2_1
U28 GS2_2
U29 GR3_1
U30 GR3_2
U31 GS3_1
U32 GS3_2
U33 GR4_1
U34 GR4_2
U35 GS4_1
U36 GS4_2
ITEM CODE:
JOB NO :
220VAC
POWER SUPPLY
YELLOW
ORANGE
GREEN L
N
YELLOW
ORANGE
GREEN
TL /Com1.C3
TH /Com1.C3
YELLOW
ORANGE
GREEN
YELLOW
ORANGE
GREEN
ITEM CODE:
JOB NO :
CAN-1 BUS
CAN1
CAN2
2WIRE TO BIG ALARM HOOTER IN EACH SYSTEM
CN.2
CAN-1 BUS
CAN1
CN.5
CAN2
ITEM CODE:
JOB NO :
CAN-1 BUS
CAN1
CAN2
CAN-1 BUS
CAN1
CAN2
ITEM CODE:
JOB NO :
GRID
220VAC
GENSET POWER SUPPLY
L
GRID N
GENSET 24+
5V1
5V2
GRID PP
GENSET PP
101
102
GRID
GENSET
GRID
GENSET
AMARA RAJA POWER SYSTEMS Ltd. Bill of Material Report Doc Ref No : ENG-SFS-08/REV 0
Sale Order No/Item No : 5200002811/010 Customer Name Amara Raja Batteries Limited Rev No 01
Item Code CDCK36005008-20DAE87 Description 360V/50A CHAR/DIS SYSTEM 8CKT/CAB QTY 34 UOM NOS
Qty/
SI No Rev Circuit Designation Input Item Code Description Alt.Grp Varint Description UOM
System
T-360V/50A CHAR/DIS SYSTEM 8CKT/
0010 01 T-CDCK36005008-20DAE87 T-360V/50A CHAR/DIS SYSTEM 8CKT/CAB 3PH-FWFC-PGCIL 1 NOS
CAB
Instruction
Report Run Date & Time 07:10:2021 14:18:56 Prepared By : 3000768 Checked By : Approved By : Page 1 of 1
Proprietary Material of M/S AMARA RAJAPOWER SYSTEMS (P) LTD., Tirupati. All rights reserved. No copying permitted. Unauthorised use prohibited.
Sale Order No/Item No : /000 Customer Name Rev No 11
Item Code F-CDCK36005008-20DAE87 Description F-360V/50A CHAR/DIS SYSTEM 8CKT/CAB QTY 0.000 UOM
Qty/
System
0010 01 1C2-8C2 11-40401312010-C091 Snubber-Metal FilmCapa-BOX -1.0uF/1200Vd MKPH-S -C105120021102 8 NOS
0020 01 1FL-8FL 11-47602110051-B011 Shunt-50A/75mV,0.2%tempcoefficient:27ppm Beemet 8 NOS
0030 01 1FU-8FU,1FU1-8FU1,1FU2-8FU2 11-47502165080-S225 FUSE-HRC-80A,500VAC Sino:NH00-T80A 24 NOS
0040 01 1FU-8FU,1FU1-8FU1,1FU2-8FU2 11-47512000075-S225 Fuse base-L*W*H*d(mm)120*30*60*dia7.5 SINO:SIST101 24 NOS
0050 01 1IGBT-8IGBT 11-40461412015-I024 IGBT module-150A-1200V Infine-FF150R12RT4 8 NOS
0060 01 1KM-8KM 11-47930456065-C070 Contactor-3P-65A-1NO+1NC-Coil vol AC230V NC1-6511 AC220V-65A 8 NOS
0070 01 1L-8L 11-42500005410-S003 Induct-HF-1.15mH,50A HF Choke,1.15mH,50A 8 NOS
0080 01 1QF1-8QF1 11-40071399105-C070 Air switch-MCB-10A-3P-AC400V NB1-63H 3P 10kA D10 8 NOS
0090 01 1QF2-8QF2,1QF3-8QF3 11-40071299805-C070 MCB-80A-2P-AC400V DZ158-125H 16 NOS
0100 01 1R2-8R2,1R3-8R3 11-40484375100-S224 Cement resistor-510R-10W±5% axial lead SQM-10W-510R-5% 16 NOS
0110 01 1RC-8RC,RC1,RC2 11-40482320100-W007 Metal film Resistor 2W-10R-5%-MFR Watts-MFR-2W-10R-5% 10 NOS
0120 01 1RC-8RC,RC1,RC2 11-42500005376-STD CBB Capacitor 104/1KV 104/1KV 10 NOS
0130 01 1TP1-8TP1,1TP2-8TP2 11-41010101000V-E014 Test socket-4mm-Red Elcom:BS-5-Red 16 NOS
0140 01 1TP3-8TP3,1TP4-8TP4 11-41010401000V-E014 Test socket-4mm-Black Elcom:BS-5-Black 16 NOS
0150 01 4CORE CABLE 11-44120240002V-STD Cable-PVC-4C-cu-UnAr.-0.22sqmm STDVendor 4.000 M
0160 01 4CORE CABLE conn 11-48900000083V-M014 Connector-4W-F-ST-2.54MM 22-01-3047 16 NOS
Qty/
System
0170 11 4core crimp 11-41100000037V-M014 Conn-Crimp Terminal-F-5159 Molex: 08-70-0064 100 NOS
0180 09 Bus Bar for DC bus SHORT 11-44191002508RR-STD Bus bar-copper-25x8sqmm Round edge 20x8sqmm Round edge 2.000 KG
0190 01 Bus bar for earthing 11-44191002506R-STD Bus bar-copper-25x6sqmm-Round edge 0.430 KG
0200 01 Bus Bar for IGBT to cap shorting 11-44191001503R-STD Bus bar-copper-15x3sqmm-Round edge 3.000 KG
0220 01 Cable 11-44144600005-S211 Cable-FR-LSH-1C-multi stnd-0.5sqmm-Brown 20.000 M
0230 01 Cable 11-44144610005-S211 Cable-FR-LSH-1C-multi stnd-0.5sqmm-RED 60.000 M
0240 01 Cable 11-44144610025-S211 Cable-FR-LSH-1C-multi stnd-2.5sqmm-RED 15.000 M
0250 01 Cable 11-44144610160-S211 Cable-FR-LSH-1C-multi stnd-16sqmm-RED 16SQMM RED 55.000 M
0260 01 Cable 11-44144610350-S211 Cable-FR-LSH-1C-multi stnd-35sqmm-RED 35SQMM-RED 9.000 M
0270 01 Cable 11-44144620005-S211 Cable-FR-LSH-1C-multi stnd-0.5sqmm-YELLO 25.000 M
0280 01 Cable 11-44144620025-S211 Cable-FR-LSH-1C-multi stnd-2.5sqmm-Yello 4.000 M
0290 01 Cable 11-44144620350-S211 Cable-FR-LSH-1C-multi stnd-35sqmm-YELLOW 35sqmm-YELLOW 9.000 M
0300 01 Cable 11-44144630005-S211 Cable-FR-LSH-1C-multi stnd-0.5sqmm-Blue 40.000 M
0310 01 Cable 11-44144630025-S211 Cable-FR-LSH-1C-multi stnd-2.5sqmm-Blue 4.000 M
0320 01 Cable 11-44144630350-S211 Cable-FR-LSH-1C-multi stnd-35sqmm-Blue 35sqmm-BLUE 9.000 M
0330 01 Cable 11-44144640005-S211 Cable-FR-LSH-1C-multi stnd-0.5sqmm-BLACK 0.5sqmm-BLACK 65.000 M
Qty/
System
0340 01 Cable 11-44144640015-S211 Cable-FR-LSH-1C-multi stnd-1.5sqmm-black 1.5sqmm-black 150.000 M
0350 01 Cable 11-44144640160-S211 Cable-FR-LSH-1C-multi stnd-16sqmm-black 16SQMM BLACK 55.000 M
0360 01 Cable 11-44144650025-S211 Cable-FR-LSH-1C-multi stnd-2.5sqmm-Green 20.000 M
0370 01 Cable 11-44144680005-S211 Cable-FR-LSH-1C-multi stnd-0.5sqmm-Grey 0.5sqmm-Grey 20.000 M
0380 01 Cable(2runs) 11-44144620500-S211 Cable-FR-LSH-1C-multi stnd-50sqmm-YELLOW 2.000 M
0390 01 Cable(2runs) 11-44144630500-S211 Cable-FR-LSH-1C-multi stnd-50sqmm-Blue 2.000 M
0400 01 Cable(Runs) 11-44144610500-S211 Cable-FR-LSH-1C-multi stnd-50sqmm-RED 3.000 M
0410 01 Cable(FA1) 11-44144610004-S211 Cable-FR-LSH-1C-multi stnd-4sqmm-RED FRLS -RED 1.000 M
0420 01 Cable(FA2) 11-44144620004-S211 Cable-FR-LSH-1C-multi stnd-4sqmm-YELLOW FRLS -YELLOW 1.000 M
0430 01 Cable(FA3) 11-44144630004-S211 Cable-FR-LSH-1C-multi stnd-4sqmm-BLUE FRLS -BLUE 1.000 M
0440 01 FA1-3 11-40413990045-Y012 Zinc oxide arrestor HY1.5W-0.28/1.3 3 NOS
0450 01 FAN1,FAN2 11-44699000150-E001 AC Centrifg Dul Inlet Blowr-270(L)x142(W EBM-D2E146AP4722(IN) 2 NOS
0460 01 FAN3,FAN4 11-44500000017-E001 Cooling Fan-240vac-115W-2550rpm IN-LET EBM-W2E250-CE65-02 2 NOS
0470 01 FAN5_1-8 11-44500000073-K067 Axialcompressorfan240V3300rpm-CFM268-65W KAKU KA1725*A22 8 NOS
0480 01 FU1-4 11-47503995010-S225 Fuse core-10A-500V-dia 10*38 Sino:FGB-A-3E 10A 4 NOS
0490 01 FU1-4 11-47512000076-S225 fuse base-690V-32A-L*W*H(mm) 80*18*60 Sino:TSA1038 4 NOS
Qty/
System
0500 01 FU5-FU8 11-47502165300-S225 Fast fuse-500V-315A RS306-000-L-315A690V 4 NOS
0510 01 Heat sink 1-8 11-44899000143-J012 Heat sink-L*W*H 200*227*90 for CKT Jindal: Q10433 8 NOS
0520 01 Heat sink 9-10 11-44899000146-STD Heat sink-L*W*H550*350*100 for inverter CDF-SRQ-550*350*100 2 NOS
0530 01 HL1 11-47711106221-E008 Indicator-AC415V-red- 22 Dia Essen-LMRD 1 NOS
0540 01 HL2 11-47711106222-E008 Indicator-AC415V-yellow- 22 Dia Essen-LMYD 1 NOS
0550 01 HL3 11-47711106224-E008 Indicator-AC415V-blue- 22 Dia Essen-LMBD 1 NOS
0560 01 KA1 11-47410131600V-P008 Relay-240VAC-panel mount-10A-mpc-3c/o PLA-3C/O-MPC-240A 1 NOS
0570 01 KA1 11-47480200311V-P008 Relay base-PNL-11pin-3C/O PLA-RS11E 1 NOS
0580 01 KM1,KM2 11-47930406330-C070 Cont-3P-330A-AC380V-Coil220VAC-2NO+2NC NXC-330,Nc/3P 2 NOS
0590 01 PC1-8* 11-42500005292-C088 Instrument case 8010-1A 8 NOS
0600 01 PC1-8* 11-42500005306-P099 MC-21-Charger controller LED mask STICKERS 8 NOS
0610 01 PC1-8* 11-42500005307-P099 Adjustment terminal mask-50A/75mV Sticker 8 NOS
0620 01 PC1-PC8 ARE22001225 PCB IGBT -CD Display & Key BD.-2L AREL-P22001225 8 NOS
0630 01 PC17-PC18 ARE22001222 PCBBi-directional Inv. Bd-CD Ckts4L AREL 2 NOS
0640 01 PC19-PC22 ARE22001228 PCB-Current Sensor Bd.-2L AREL-P22001228 4 NOS
0650 01 PC23 ARE22001232 PCB-MID Control Power Supply Bd-2L AREL-P22001232 1 NOS
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System
0660 01 PC24-25 ARE22001229 PCB-DC BUS Power Light.Bd-2L AREL-P22001229 2 NOS
0670 01 PC26-PC33 ARE22001230 PCB-DC BUS Capacitor Bd-2L AREL 8 NOS
0680 01 PC34-PC39 ARE22001227 PCB-Driver Bd. 50-300A.-2L AREL-P22001227 6 NOS
0690 01 PC40-PC47 ARE22002226 PCB-Driver Bd. 30-40A.-Gate Res 5R AREL 8 NOS
0700 01 PC9-PC16 ARE22001224 PCB DC-DC Bi-Dir Conv 30-150A BD-2L AREL-P22001224 8 NOS
0710 01 PC(17-18) (JA,JB),PC19-PC22 11-44150000010V-F004 Cable-flatRibbon-10core-28AWG FARCOM 4.000 M
0720 01 PC(17-18)(JA,JB),PC19-PC22 11-41100000112V-O001 Connector-oen-dil-ST-F-10W 8613-010-31-30-345E1 8 NOS
0730 01 PC(17-18)J1,PC23(JK1) 11-41100000897-P022 Conn-ST-F-03W-5.08mmP-Box-Screw 5441977 3 NOS
PC(17-18)JK1,PC23(JK2 & C(9-16)(JK1)

0740 06 11-41100000898-P022 Conn-ST-F-04W-5.08mmP-Box-Screw 5448637 13 NOS
PC23(JK3)
0750 01 PC(17-18)J8, J9, J10,PC(9-16)(JK5) 11-41100000899-P022 Conn-ST-F-05W-5.08mmP-Box-Screw 5448640 14 NOS
0760 01 PC(17-18)J6 11-41100000900-P022 Conn-ST-F-09W-5.08mmP-Box-Screw 5448653 2 NOS
0770 01 PC(17-18)J7 11-41100000901-P022 Conn-ST-F-08W-5.08mmP-Box-Screw 5441951 2 NOS
0780 01 PC(9-16)(JK3) 11-41100000902-P022 Conn-ST-F-02W-5.08mmP-Box-Screw 5441980 8 NOS
0790 01 PC(9-16)(JK4) 11-41100000903-P022 Conn-ST-F-06W-5.08mmP-Box-Screw 5441964 8 NOS
0800 01 QF1 11-40070133715-C070 Rotary Handle for NM1-400S/3300-400A RS FOR NM1-400S/3300 1 NOS
0810 01 QF1 11-48631990095-C070 3phase MCCB-350A-3P-AC 690V NM1-400S/3300 350A 1 NOS
Qty/
System
0820 01 QF1* 11-42500005670-C070 Spreaders 3Pole- NM1-400S MCCB Spreaders 6 NOS
0830 01 QF10,QF11,QF12 11-40071299105-C070 Air switch-MCB-10A-2P-AC400V NB1-63H 2P 10kA D10 3 NOS
0840 01 QF13-15,QF17,QF18 11-40071199105-C070 Air switch-MCB-10A-1P-AC400V NB1-63H 1P 10kA D10 5 NOS
0850 01 R1 11-40482301530-S224 Metal aluminumcoverresistor-300R-150W-5% RX24-150W-300R-5% 3 NOS
0860 01 S1 11-40072110110V-R003 Toggle switch-pm-SPST-ON/OFF-10A RECOM-RT121B 1 NOS
0870 01 SC1 11-42500000245V-A008 SOCKET-3PIN-5A Anchor 1 NOS
0880 01 TC1-Power control Txfr 43200005322 Control Xformer-415V/180V-150VA ARP-AT-5322 1 NOS
0890 01 TM1-Main Transformer 43200005335 Char I/P Xfr 415/135VLNX2NOs&158.4KVA ARP-AT-5335 1 NOS
0900 01 V1C1,V1C2,V1C4,V2C1,V2C2,V2C4 11-40401312020-C091 Snubber-Metal Film Capa-BOX -2uF/1200Vdc MKPH-S -C205120021104 6 NOS
V1C3_(1-2),V1C5_(1-2),V2C3_(1-2),V2C5_
0910 01 11-40715003300-B074 WES_3300uf,500V.76X130105deg2000h WE500M332SW76*130 16 NOS
(1
0920 01 V1IGBT1-3,V2IGBT1-3 11-40461412040-I024 IGBT module-450A-1200V Infineon FF450R12KT4 6 NOS
0930 01 V1L,V2L-AC Choke 43200005379 Charge 3 Ph AC Choke0.6mH-360V,50A-I CRN ARP-AT-5379 2 NOS
0940 01 V1NT1-3,V2NT1-3,1NT-8NT 11-40488308000-K066 Temp switch -85deg KSD301 85deg NC 14 NOS
0950 01 V1R1,V1R2,V2R1,V2R2 11-40483393000-S224 Power by glazewindingResistor-30R-50W±5% RX20-50W-30R-5% 4 NOS
V1R3_(1-2),V1R4_(1-2),V2R3_(1-2),V2R4_
0960 01 11-40484354700-S224 Cement resistor-47K-5W±5% axial lead SQM-5W-47K-5% 8 NOS
(1
0970 01 Woven belt 11-42500005298-STD Woven belt W(37MM)XT(3mm) STD 4.200 M
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System
0980 01 I-bolt 11-42500005299-P103 CD system Woven belt i-Bold Pyramid-NEB-8 6 NOS
0990 01 X1 11-41004001045V-E015 Terminal Block-Power-76A-Single-M5 ELMEX-CBTM5 2 NOS
1000 01 HBL1 11-42500005303-STD Tower LEDLAMP Red withBuzzer for CD STD VENDOR 1 NOS
1010 01 ELECTROLYTE TEMP SENSING PCB 11-42500005293-C088 PCB-4X6temp Batt Electrolyte temp sense CTIST-BMS-4x6TEMP 1 NOS
1020 03 ELECTROLYTE TEMP SENSOR 11-42500005297-P114 Electrolyte temp sensor-18b20,10mmX1m 18B20,10MMX1M-170TE 8 NOS
ELECTROLYTE TEMP SENSOR

1030 04 11-44110040202-R061 Cable-3C-0.22sq tnd coper + Drain Wr shl 3C With Shiled 400.000 M
CONNECTING CABLE
ELECTROLYTE TEMP PCB BOX +
1040 01 11-42500005661-C088 Acid proof box Acid proof box 1 NOS
CABLE GLAND
1050 02 CABINET 49011010592 Cab-360V,50A CD 8-ckt H2150xW1200xD1100 1 NOS
1060 08 IGBT shorting in inverter section 11-44191002005RR-STD Bus bar-copper-20x5sqmm Round edge 20x5sqmm Round edge 2.600 KG
1070 10 R-phase and Y pahse CT busbar 11-44191001506-STD Bus bar-copper-15x6sqmm STD Vendor 1.000 KG
Instruction
Sale Order No/Item No : 5200002811/060 Customer Name Amara Raja Batteries Limited Rev No 05
Item Code DCP-SPAR1204-20SAM82 Description COMMUNI+GENGRD WITH PC 360V/50A CD 8 CKT QTY 2 UOM SET
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System
0010 01 CAN/WAN communication CAN-WAN-MOD CAN-WAN-Module-IGBT-CD Ciricuits V.0 CAN-WAN-V.0 4 NOS
ALARM PC((Should be placed in CD system

0020 04 11-42500005774-C088 PCB-Alarm extension-6sys-CD system CEMT-CD alarm 4 NOS
Right side bottom door)
0030 01 Communication PC 11-42500005295-STD Industrial grade PC-OPTIPLEX XE3 Intel core i5-8500 1 NOS
0040 01 PC Monitor 11-42500005777-STD PC monitor Industrial Grade 21inch STD VENDOR 1 NOS
0050 01 LAN CARD FOR PC 11-42500005296-STD PCI-Express Desktop Lan Card lan CARD 1 NOS
0060 01 GENSET/GRID 11-42500005294-C088 PCB-GENSET/GRID sense BD CTIST-AC POWER STT 1 NOS
0070 01 Network switch 11-42500005215-D033 8 Port ethernet switch-Un managed D-Link 1 NOS
0080 01 CAN-WAN-MOD(CN0) 11-41100000902-P022 Conn-ST-F-02W-5.08mmP-Box-Screw 5441980 4 NOS
0110 01 CAN-WAN-MOD(CN9) 11-41100000880-P022 Conn-Term Block plug 3W-RA- 3.81mmP 1827716 4 NOS
SPARE LAMP(Should be placed on on CD

0130 05 11-47718105221-E084 indicator with alarm-AC230V-dia22-RED Encore:EIB-01,220VAC 27 NOS
sys Right side bottom door)
Instruction

ABD3 MANUAL-360V-50A CD SYSTEM New PDF

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Operation manual

Busbar Type Storage Battery Charger

This machine is suitable for battery charging and discharging and

1.2 Control system

The machine adopts MCU automatic control equipment with a new

the output circuit disconnection alarm, busbar voltage alarm, battery

parameters read error alarm, program download error alarm, etc

Working mode of Charge-discharge include constant-current

charging, constant-current voltage limiting charging, constant-voltage

current limiting charging, constant-current discharging, constant-current

constant-pressure discharging, stewing, recycling, time setting, voltage

setting, Ah setting transformation function. Controller has a strong record

running as well as real-time clock for analyzing problems of battery

used in automotive electronic devices used with a high-speed and reliable

The machine contains programming convenience, high precision,

stable running, safe and reliable features.

Remark Different Voltage Current and Circuits can be customized.

Control methods: Digital Tube Display micro-computer controller

Process parameter group number: 1groups

Setting method: Control panel keyboard settings or the a

remote settings of computer

Range of parameter setting:

Time 00 :00 ~99 :59

Range of parameter controlling:

Voltage 10% F.S~100% F.S

Current 1% F.S~100% F.S

2.3 Machine Technical Requirements

Power: 3 Phase AC380V (+10%~-5%); frequency is 50HZ±10%

Voltage details should be customized

according to local situation for foreign clients

Full load power consumption: Rated charge current*Rated output

Sea level: Below 1000m

Humidity: Below 90% nocondensation

Ambient temperature: -5~50

Net voltage fluctuation: Volatility of less than 5%, short-term

fluctuations should not exceed ± 10%

Frequency fluctuations: Below 2%, frequency and network pressure

Installation environment: Without severe vibration and shock, slope

less than 5%, no conductive explosive dust and corrosive

gases or acid gases, operating rooms should be separated

with formation workshops

Date set storage period: 10 years

After data input, if the controller is in normal operation

ten years. The data may be destroyed when there’s malfunction

Is strongly recommended that users to the important process

parameters are written down to prevent data loss

Current precision ±0.5% F·S F·S=

Voltage precision ±0.5% F·S F·S=

Time precision 24H±15S

This machine is fully automatic machine with high demand, which

specification carefully before operating this machine. After reading,

please will be kept the manual provisions in place;

position of the machine.

operation and maintenance of this machine.

2.2. Be sure there is enough space around this machine before

installation so that your engineers or technologys can inspect and

2.3. For charging and discharging machine top mounted a heating

distance and workshop in the top no combustible goods.

wall space or other wall space or other